Protective drainage wraps

ABSTRACT

A protective drainage wrap includes a mesh and a coating applied to the mesh. The coating is applied to the mesh to form a plurality of interstices, the interstices being configured to facilitate transfer of water vapor therethrough. The mesh includes material extending in a first direction and in a second direction. The material in the first direction includes a polyolefin, polyester, nylon or combinations thereof and has a first thickness. The material in the second direction includes a polyolefin, polyester, nylon or combinations thereof and has a second thickness. The second thickness is at least about twice the first thickness so as to assist in providing drainage for moisture build-up. The material in the second direction can be yarn. The coating includes a polyolefin, polyester, nylon or combinations thereof. A process for the preparation of the protective drainage wrap is provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/869,333, filed Jun. 16, 2004, which is a division of U.S. applicationSer. No. 10/255,273, now U.S. Pat. No. 6,869,901, which is acontinuation-in-part of U.S. application Ser. No. 09/788,776 filed Feb.20, 2001, now U.S. Pat. No. 6,550,212 which is entitled “ProtectiveDrainage Wraps” Each above application is incorporated herein byreference in

BACKGROUND

1. Field of the Invention

The present invention relates generally to protective wraps that areused to protect against air infiltration and moisture build-up inbuildings. Specifically, the protective wraps of the present inventioninclude cross-woven or cross-laminate materials.

2. Background of the Invention

There have been many different commercial protective wraps used in theconstruction of buildings, such as residential and commercialconstruction. Commercial protective wraps are used to protect againstair infiltration and damaging moisture build-up. Air infiltration mayoccur in typical construction through, among other places, sheathingseams and cracks around windows and doors. Moisture buildup can occurexternally in the wall cavity from, for example, leaking exteriorfinishes or coverings, and cracks around windows and doors. The exteriorof the protective wraps should not trap the water, but rather allow itto flow downward so as to exit the wall system.

Commercial protective wraps are typically used as secondary weatherbarriers in buildings behind exterior finishes or coverings such assiding, brick, stone, masonry, stucco and concrete veneers. Stucco maybe synthetic based (e.g., a polymer-based stucco) or cementitious (amixture of Portland cement, lime and sand). One type of stucco system,exterior insulation finish system (drainage EIFS), that is used inbuildings typically involves using a drainage plane, an insulationboard, and a wire or synthetic mesh that accepts a cementitious coating.In stucco systems, protective wraps are not typically installed directlyin contact with the cementitious coatings. In some instances, multiplelayers of protective wrap are installed with one layer contacting thecementitious coatings.

Both woven and non-woven commercial protective wraps are commonly usedin the construction of buildings. The strength properties of woven wrapsare typically much higher than the strength properties of non-wovenwraps. Some woven wraps are translucent, which assist in locating studs,as well as window and door openings. Non-woven wraps, however, may havehigher permeabilities than woven wraps.

Commercial protective wraps, such as non-woven wraps, woven wraps andcross-laminated wraps, also may be micro-perforated so as to allowmoisture vapor to pass therethrough. Most non-woven commercialprotective wraps (such as spun bonded polyolefin wraps) are notperforated because the processes used in forming the wraps result in astructure that inherently allows the moisture vapor to pass through thewrap.

Accordingly, a need exists for a protective wrap that enhances drainageof damaging moisture build-up, while still protecting against airinfiltration.

SUMMARY OF THE INVENTION

According to one embodiment, a protective drainage wrap includes a meshand a coating applied to the mesh. The coating is applied to the mesh toform a plurality of interstices, the interstices being configured tofacilitate transfer of water vapor therethrough. The mesh includesmaterial extending in a first direction and in a second direction. Thematerial in the first direction includes a polyolefin, polyester, nylonor combinations thereof and has a first thickness. The material in thesecond direction includes a polyolefin, polyester, nylon or combinationsthereof and has a second thickness. The second thickness is at leastabout twice the first thickness so as to assist in providing drainagefor moisture build-up. The material in the first direction can be thesame as or different from the material in the second direction. Thematerial in the second direction can also be yarn. The material in thefirst direction and in the second direction can include a plurality oftapes. The coating includes a polyolefin, polyester, nylon orcombinations thereof. The coating of the preferred embodiment has athickness between about 0.5 mil and 2.0 mils. The first directionmaterial and the coating of the preferred embodiment have a combinedthickness between about 8 mils and 10 mils. The protective drainage wrapcan be cross-woven or cross-laminated, and can include a plurality ofperforations formed therethrough. If included, the perforations can bebetween about 3 to 15 mils. The application of the coating with apredetermined thickness to the mesh to form a plurality of intersticesof predetermined size controls the permeability of the protectivedrainage wrap.

According to a method of the present invention, a protective drainagewrap is prepared by providing a mesh, and applying a coating to the meshso as to form a plurality of interstices configured to facilitatetransfer of water vapor therethrough. The mesh includes materialextending in a first direction and in a second direction. The materialin the first direction includes a polyolefin, polyester, nylon orcombinations thereof and has a first thickness. The material in thesecond direction includes a polyolefin, polyester, nylon or combinationsthereof and has a second thickness. The second thickness is at leastabout twice the first thickness so as to assist in providing drainagefor moisture build-up. The material in the first direction can be thesame as or different from the material in the second direction. Thematerial in the second direction can also be yarn. The material in thefirst direction and in the second direction can include a plurality oftapes. The coating includes a polyolefin, polyester, nylon orcombinations thereof. The coating of the preferred embodiment has athickness between about 0.5 mil and 2.0 mils. The first directionmaterial and the coating of the preferred embodiment have a combinedthickness between about 8 mils and 10 mils. The protective drainage wrapcan be cross-woven or cross-laminated, and can include a plurality ofperforations formed therethrough. If included, the perforations can bebetween about 3 to 15 mils. The application of the coating with apredetermined thickness to the mesh to form a plurality of intersticesof predetermined size controls the permeability of the protectivedrainage wrap.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a cross-woven protective wrapaccording to one embodiment;

FIG. 2 is a cross-sectional view taken generally along line II-II ofFIG. 1;

FIG. 3 is a top perspective view of a cross-laminated protective wrapaccording to one embodiment;

FIG. 4 is a cross-sectional view taken generally along line IV-IV ofFIG. 3;

FIG. 5 is a cut-away perspective view of a protective wrap of FIG. 1fastened to sheathing and a framing member according to one embodiment,

FIG. 6 is a top perspective view of a yarn cross-woven protective wrapaccording to another embodiment,

FIG. 7 is a cross-sectional view taken generally along line VII-VII ofFIG. 6;

FIG. 8 is a cut-away perspective view of a protective wrap of FIG. 6fastened to sheathing and a framing member according to anotherembodiment;

FIG. 9 is a top perspective view of a yarn protective wrap according toyet another embodiment;

FIG. 10 is a cross-sectional view taken generally along line X-X of FIG.9;

FIG. 11 is a top perspective view of a cross-woven protective wrapaccording to one embodiment,

FIG. 12 is a cross-sectional view taken generally along line XII-XII ofFIG. 11;

FIG. 13 is a top perspective view of a cross-laminated protective wrapaccording to another embodiment of the present invention,

FIG. 14 is a cross-sectional view taken generally along line XIV-XIV ofFIG. 13,

FIG. 15 is a cut-away perspective view of a protective wrap of FIG. 11fastened to sheathing and a framing member according to anotherembodiment of the present invention,

FIG. 16 is a top perspective view of a yarn cross-woven protective wrapaccording to yet another embodiment of the present invention;

FIG. 17 is a cross-sectional view taken generally along line XVII-XVIIof FIG. 16, and

FIG. 18 is a cut-away perspective view of a protective wrap of FIG. 16fastened to sheathing and a framing member according to yet anotherembodiment of the present invention

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Itshould be understood, however, that it is not intended to limit theinvention to the particular forms disclosed but, on the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the invention as defined by theappended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings and referring initially to FIGS. 1 and 2, aprotective drainage wrap 10 according to one embodiment is shown. Theprotective wraps of the present invention, including protective wrap 10,are adapted to be attached over sheathing or framing members. Theprotective wraps are typically covered by an exterior covering such assiding, brick, stone, masonry, stucco (e.g., synthetic or cementitious)or concrete veneer.

According to one embodiment, the protective wrap 10 of FIGS. 1 and 2includes a first portion or mesh 12 and a second portion or coating 14.The first portion 12 of the protective wrap 10 may be cross-woven suchas shown in FIGS. 1 and 2. Alternatively, the first portion of thepresent invention may be cross-laminated, such as shown in FIGS. 3 and 4with cross-laminated protective drainage wrap 20.

First Portion or Mesh

The first portion of the protective wrap provides a desirable strengththat assists in inhibiting or preventing tears and/or fraying that maybe caused during installation. These tears and/or fraying may be causedby, inter alia, nails or staples during the installation of theprotective wraps. These tears and/or fraying may also be caused afterinstallation by environmental conditions such as the wind or byvandalism before the protective wrap is covered with an exteriorcovering.

The first portion 12, as shown in FIG. 1, includes a plurality ofmachine (e.g., first) direction (MD) tapes or strands 12 a and aplurality of transverse (e.g., second) direction (TD) tapes or strands12 b. The machine direction is also referred to as “warp”, while thetransverse direction is also referred to as “fill” or “weft”. The firstportion 12 of FIG. 1 is commonly referred to as a cross-woven scrim.

The scrim shown in FIG. 1 is a 10×4 count scrim (MD number per inch×TDnumber per inch) that has been enlarged. It is also contemplated thatvarious other scrim counts may be used, including a 7×4 count, a 10×5count, a 16×4 count, and a 16×5 count, in forming the first portion 12of the present invention. The scrim count is typically a greater numberin the machine direction than the transverse direction. The MD scrimcount is generally from about 6 to about 24 tapes per inch, while the TDscrim count is generally from about 3 to about 6 tapes per inch. The MDand TD scrim counts are generally lesser in number per inch as therespective widths of the MD and TD tapes are increased.

The plurality of machine direction tapes 12 a may be made of materialssuch as polyolefins, polyesters, nylons or combinations thereof.Polyolefins that may be used in forming the machine direction tapes 12 ainclude polypropylenes or polyethylenes. The term “polypropylene” asused herein includes polymers of propylene or polymerizing propylenewith other aliphatic polyolefins, such as ethylene, 1-butene, 1-pentene,3-methyl-1-butene, 4-methyl-1-pentene, 4-methyl-1-hexene,5-methyl-1-hexene and mixtures thereof. Polypropylene not only includeshomopolymers of propylene, but also propylene copolymers comprised of atleast 50 mole percent of a propylene unit and a minor proportion of amonomer copolymerizable with propylene and blends of at least 50 percentby weight of the propylene homopolymer with another polymer.

The term “polyethylene” as used herein includes low density polyethylene(LDPE), medium density polyethylene (MDPE), high density polyethylene(HDPE), very low density polyethylene (VLDPE), linear low densitypolyethylene (LLDPE), metallocene-catalyzed linear low densitypolyethylene (mLLDPE) and combinations thereof.

An example of a “polyester” includes a polyester resin which is apolycondensation product of a dicarboxylic acid with a dihydroxyalcohol. An example of a “polyethylene terephthalate” includes apolyester resin made from ethylene glycol and terephthalic acid. Anexample of a “nylon” is a polyamide polymer, that is a polycondensationproduct of a dicarboxylic acid with a diamine, and that is characterizedby the presence of an amide group (—CONH—.)

Each of the plurality of machine direction tapes 12 a may be made of asingle fiber or filament, or a plurality of fibers or filaments alignedwith each other. It is contemplated that the plurality of machinedirection tapes 12 a may be made of a mixture of single fibers orfilaments, and a plurality of fibers or filaments aligned with eachother. For example, the single fibers or filaments may be alternatedwith the plurality of filaments aligned with each other such that thethicknesses of the plurality of machine direction tapes 12 a vary. Themachine direction tapes 12 a may also be referred to as cords. As shownin FIG. 1, the plurality of machine direction tapes 12 a aresubstantially flat.

The plurality of transverse direction tapes 12 b may be made ofmaterials such as polyolefins, polyesters, nylons or combinationsthereof as described above with respect to the machine direction tapes12 a. Polyolefins that may be used in forming the transverse directiontapes 12 b include polypropylenes and polyethylenes. Each of theplurality of transverse direction tapes 12 b may be made of a singlefibers or filaments, or a plurality of fibers or filaments aligned witheach other. It is contemplated that the plurality of transversedirection tapes 12 b may be made of a mixture of single fibers orfilaments, and a plurality of fibers or filaments aligned with eachother. For example, the single fibers or filaments may be alternatedwith the plurality of filaments aligned with each other such that thethicknesses of the plurality of transverse direction tapes 12 b vary.The transverse direction tapes 12 b may also be referred to as cords. Asbest shown in FIG. 2, each of the transverse direction tapes 12 b isshaped in a generally oval manner. The plurality of transverse directiontapes 12 b are preferably substantially circular or circular in shape.The transverse direction tapes 12 b are shaped in a manner that willallow water to flow down the channels formed between the transversedirection tapes 12 b via gravity.

If natural vapor transmission is desired in a woven protective wrap, thetransverse direction tapes 12 b must be of a sufficient thickness toenable a natural vapor transmission to be formed when the coating 14 isapplied to the first portion 12. The natural vapor transmissionmechanism is formed via open interstices/spaces along the transversedirection tapes 12 b after the coating 14 is applied. A protective wrapwith open interstices/spaces may not require physical perforations tomeet typical building code requirements for water vapor transmission.

The protective wrap with open interstices/spaces may be perforated toenhance natural vapor transmission. If the protective wrap is formedwithout interstices/spaces, the protective wrap often is perforated toprovide for desirable water vapor transmission. The size and shape ofthe perforations formed in the protective wrap may vary. If theperforations are substantially circular, the diameter of theseperforations is generally from about 3 to about 15 mils. The spacing ofthe perforations formed in the protective wrap may also vary withrespect to each other. One example of spacing that may be used betweenthe perforations in the protective wrap is about 3/16 of an inch.

Natural vapor transmission is often desirable because of moisturebuild-up occurring from internal moist air present in the wall cavity.Moisture build-up may occur from materials, such as green lumber, usedin framing or structural sheathing. Moisture build-up may also occurfrom environmental elements, such as rain, during construction before anexterior finish has been installed or water that enters the installedwall system.

The thicknesses of transverse direction tapes 12 b of the presentinvention provide unique vertical channels, when installed, that enhancemoisture drainage external to the protective wrap (i.e., between theprotective wrap and the exterior finish). The installed transversedirection tapes 12 b allow water to readily exit a wall system. Toenhance moisture drainage, the thickness of the transverse directiontapes 12 b is generally at least about 2 times greater than thethickness of the machine direction tapes 12 a. The thickness of thetransverse direction tapes 12 b is generally at least about 3 or about 4times greater than the thickness of the machine direction tapes 12 a.The thickness of the transverse direction tapes 12 b may be from about 6to about 8 times greater than the thickness of the machine directiontapes 12 a.

The plurality of transverse direction tapes 12 b according to oneembodiment is shown in FIG. 5 after being installed. The transversedirection tapes 12 b are generally perpendicular to the machinedirection tapes 12 a so as to enhance moisture drainage. It iscontemplated that the tapes 12 b may be located generally diagonallywith respect to the tapes 12 a as long as the tapes 12 b are in agenerally downward position when installed.

The first portion 12 including a plurality of MD and TD tapes 12 a and12 b may be made from an extrusion process. After being formed, thetapes 12 a and 12 b may be cross-woven by different processes. Onecontemplated process for weaving the tapes 12 a and 12 b together isthrough the use of a loom.

Alternatively, the MD and TD tapes 12 a and 12 b may be cross-laminatedto each other by adhering the tapes 12 a and 12 b together via the useof a suitable adhesive (see FIGS. 3 and 4) The adhesive is selectedbased on the materials used to form the tapes 12 a and 12 b.

Second Portion or Coating

The second portion or coating 14 of the protective wrap 10 is applied tothe first portion 12. The coating 14 may be made from polyolefins,polyesters, nylons or combinations thereof as discussed above withrespect to the first portion 12. Polyolefins that are typically used informing the coating 14 include polypropylenes and polyethylenes. Acoating 14 made from polypropylene is desirable because of the enhancedstiffness provided to the protective wrap.

The coating 14 of the present invention is generally applied to obtain athickness of from about 0.5 mil to about 2.0 mils, and preferably fromabout 0.8 to about 1.2 mil. The coating is preferably applied in asufficient thickness to the first portion 12 so that a natural vaportransmission is formed via interstices that allow the passage of watervapor.

The coating 14 is shown as being applied to one surface of the firstportion 12 in FIG. 2. It is contemplated that the coating 14 may beprovided on both surfaces of the first portion 12 (not shown) as long asthe coating 14 enables the transverse direction tapes 12 b to stillprovide channels that enhance moisture drainage, external to theprotective wrap.

The coating 14 may be applied by various processes to the first portion12. According to one process of the present invention, pellets of aresin(s) for forming the coating 14 are added in their solid form intoan extrusion hopper. These pellets are heated to a sufficienttemperature in an extruder to form a molten material. The moltenmaterial that will form the coating 14 exits the extruder through a die.The extruder typically has a horizontal die in which the molten materialexits and falls vertically by gravity onto a surface of the firstportion 12. At the same time the molten material is exited from theextruder, the first portion 12 proceeds in a direction transverse to theextruder.

The first portion 12 may proceed on a transport mechanism involvingrollers that pull the cross-woven or cross-laminated material along athreaded path. The transport mechanism is located below the extruder diethat extrudates the coating. The amount of coating 14 applied to thefirst portion 12 depends on factors such as the speed of the transportmechanism, size of the extruder die opening, and speed of the coatingexiting the die. These variables should preferably be controlled toobtain a desired thickness of the coating so as to form interstices thatallow for the passage of water vapor.

Yarn Portion

According to another embodiment, a protective drainage wrap 60 is shownin FIGS. 6 and 7. As discussed above with respect to protective wrap 10,the protective wrap 60 is adapted to be attached to sheathing or framingmembers. The protective wrap 60 includes a tape or strand portion 62, ayarn portion 64 and a coating portion 66. The tape portion 62 of FIGS. 6and 7 includes a plurality of tapes in the machine direction, while theyarn portion 64 includes a plurality of yarn strands in the transversedirection.

The yarn portion 64 is capable of absorbing moisture such as water.Additionally, the yarn portion 64 may be capable of wicking the moisturewhich may provide further enhancement to the hydration properties. Toassist in moving the water downwardly via gravity, the yarn portion 64is preferably installed in a generally vertical position. In addition,the yarn portion 64 provides a channeling effect between the pluralityof yarn strands to assist in moving the water downwardly. If the channelformed between adjacent yarn strands is blocked by, for example, stucco,then the water may be absorbed by the yarn. This absorbed water may flowdownwardly via the yarn strand or may be transported to another channelfor moving the water downwardly.

Types of yarn that may be used in the present invention include spunyarn, bulk continuous process (bcp) yarn and natural yarn (e.g., jute).Spun yarn may be formed by a two step process in which very smallfilaments are extruded and chopped to a selected length. These filamentsare then spun into a continuous yarn using, for example, a spinningframe Bulk continuous process yarns may be formed by extruding 70 or 80very small fibers into continuous filaments that are spaced in closeproximity to each other. The close proximity of the continuous filamentsallows for the filaments to be intertwined by air entanglement ortwisting to create a single yarn.

The yarn portion 64 may be made of polymeric materials such aspolyolefins, polyesters, nylons or combinations thereof. Somecontemplated polyolefins to be used in forming the yarn portion 64include polypropylenes or polyethylenes. Each of the plurality ofstrands of the yarn portion 64 shown in FIG. 6 is made of a plurality offibers or filaments twisted with each other. It is contemplated that thestrands of yarn portion 64 may have varying numbers of fibers orfilaments twisted with each other such that the thicknesses of thestrands differ. For example, the strands of yarn portion 64 mayalternate the number of fibers or filaments twisted with each other toprovide strands of varying thicknesses. One type of yarn that iscontemplated is a spun polypropylene yarn that is manufactured by BPAmoco Fabrics. The tape portion 62 and the yarn portion 64 may be bothmade from polypropylenes.

The tape portion 62 may be made of materials such as polyolefins,polyesters, nylons or combinations thereof. Examples of such materialsare described above with respect to the first portion 12 includingpolypropylenes or polyethylenes. The tape portion 62 may be made in asimilar manner as described above with respect to the machine directiontape 12 a.

The yarn portion 64 and the tape portion 62 are preferably located indirections that are generally perpendicular to each other. This locationof the yarn portion 64 with respect to the tape portion 62 is depictedin FIG. 6. It is contemplated, however, that the yarn portion 64 may belocated generally diagonally from the tape portion 62 as long as theyarn portion 64 is in a generally downward position when installed.

As depicted in FIG. 6, each of the plurality of yarn strands of the yarnportion 64 is woven between the plurality of tapes/strands of the tapeportion 62. When cross-woven, the combination of the yarn portion 64 andthe tape portion 62 may be referred to as a cross-woven scrim. The yarnportion 64 and the tape portion 62 may be woven by various techniques.One such example is with the use of a loom that weaves the yarn portion64 and the tape portion 62.

Alternatively, the tape portion 62 and the yarn portion 64 may becross-laminated (not shown) by adhering the plurality of tapes andplurality of yarn strands together via the use of a suitable adhesive.

The coating 66 may be made from polyolefins, polyesters, nylons andcombinations thereof as discussed above with respect to the coating 14.Polyolefins that are typically used in forming the coating 66 includepolypropylenes and polyethylenes. A coating 66 made from polypropyleneis desirable because of the enhanced stiffness provided to theprotective wrap. The thickness of the coating 66 is similar to thatdescribed above with respect to the coating 14. The coating 66 may beapplied to the tape portion 62 and the yarn portion 64 by the sameprocesses as described above with respect to coating 14.

Referring to FIGS. 9 and 10, a protective drainage wrap 90 includes asolid sheet portion 92 and a yarn portion 94 according to yet anotherembodiment. The protective wrap 90, as discussed above with respect toprotective wraps 10, 20 and 60, is adapted to be attached over sheathingor framing members.

To assist in draining the moisture via gravity, the yarn portion 94 ispreferably installed in a generally vertical position (i.e., thetransverse direction material). The yarn portion 94 is similar to thatdescribed above with respect to yarn portion 64. The protective wrap 90may include perforations therein to assist in increasing the water vaportransmission rate.

The solid sheet portion 92 may be made of polymeric materials such aspolyolefins, polyesters, nylons or combinations thereof. The solid sheetportion 92 may be a breathable film. Similarly, the yarn portion 94 maybe made of polymeric materials such as polyolefins, polyesters, nylonsor combinations thereof. Alternatively, the yarn portion may becross-woven through a solid sheet tape portion having a plurality ofholes therein (not shown).

The protective drainage wrap may include a solid sheet portion and aplurality of transverse direction tapes, such as the transversedirection tapes 12 b described above. The plurality of tapes areinstalled so as to assist in providing drainage for moisture build-up.

Turning to FIGS. 11 and 12, a protective drainage wrap 110 according toone embodiment of the present invention is shown. The drainage wrap 110includes a first portion 112, a second portion or coating 114 and asolid sheet portion 116. The first portion 112 of the protective wrap110 may be cross-woven such as shown in FIGS. 11 and 12. Alternatively,the first portion of the present invention may be cross-laminated, suchas shown in FIGS. 13 and 14 with cross-laminated protective drainagewrap 120. The protective wraps are adapted to be attached over sheathingor framing members.

As discussed above, the first portion of the protective wrap provides adesirable strength that assists in inhibiting or preventing tears and/orfraying that may be caused during installation. The first portion 112,as shown in FIG. 11, includes a plurality of machine direction (MD)tapes or strands 112 a and a plurality of transverse direction (TD)tapes or strands 112 b. The first portion 112 of FIG. 11 is commonlyreferred to as a cross-woven scrim.

The materials, structure (e.g., size and shape), and scrim counts of thefirst portion 112 may be the same as described above with respect tofirst portion 12. For example, the plurality of tapes or strands, 112 a,112 b may be made of materials such as polyolefins, polyesters, nylonsor combinations thereof. The scrim count is typically a greater numberin the machine direction than the transverse direction. Each of theplurality of machine direction and/or transverse direction tapes 112 a,112 b may be made of single fibers or filaments, or a plurality offibers or filaments aligned with each other. It is contemplated that theplurality of machine direction and transverse direction tapes 112 a, 112b may be made of a mixture of single fibers or filaments, and aplurality of fibers or filaments aligned with each other. For example,the single fibers or filaments may be alternated with the plurality offibers or filaments aligned with each other such that the thicknesses ofthe tapes vary.

If natural vapor transmission is desired in a woven protective wrap, thetransverse direction tapes 112 b must be of a sufficient thickness toenable a natural vapor transmission to be formed when the coating 114 isapplied to the first portion 112. The natural vapor transmissionmechanism is formed via open interstices/spaces along the transversedirection tapes 112 b after the coating 114 is applied. The protectivewrap with open interstices/spaces may be perforated to enhance naturalvapor transmission. If the protective wrap is formed withoutinterstices/spaces, the protective wrap often is perforated to providefor desirable water vapor transmission.

The thicknesses of the transverse direction tapes 112 b of the presentinvention provide unique vertical channels and, when installed, allowwater to readily exit a wall system. To enhance moisture drainage, thethickness of the transverse direction tapes 112 b is generally at leastabout 2 times greater than the thickness of the machine direction tapes112 a. The thickness of the transverse direction tapes 112 b isgenerally at least about 3 or about 4 times greater than the thicknessof the machine direction tapes 112 a. The thickness of the transversedirection tapes 112 b may be from about 6 to about 8 times greater thanthe thickness of the machine direction tapes 112 a.

The plurality of transverse direction tapes 112 b according to oneembodiment of the present invention is shown in FIG. 15 after beinginstalled. The transverse direction tapes 112 b are generallyperpendicular to the machine direction tapes 112 a so as to enhancemoisture drainage. It is contemplated that the tapes 112 b may belocated generally diagonally with respect to the tapes 112 a as long asthe tapes 112 b are in a generally downward position when installed.

The second portion or coating 114 of the protective wrap 110 is appliedto the first portion 112. The coating 114 may be made of the samematerials and thicknesses as described above with respect to coating 14.For example, the coating 114 may be made from polyolefins, polyesters,nylons or combinations thereof. The coating 114 is shown as beingapplied to one surface of the first portion 112 in FIG. 12. It iscontemplated that the coating 114 may be provided on both surfaces ofthe first portion 112 (not shown) as long as the coating 114 enables thetransverse direction tapes 112 b to still provide channels that enhancemoisture drainage, external to the protective wrap. The coating 114 maybe applied by the same processes to the first portion 112 as describedabove with respect to the coating 14 and the first portion 12.

The solid sheet portion 116 may be made of polymeric materials such aspolyolefins, polyesters, nylons or combinations thereof. The solid sheetportion 116 may be a breathable film. It may be desirable to use abreathable film because it allows the internal wall structure to breathein a similar manner as building paper. The breathable film allows watervapor to exit while preventing or inhibiting water flow therethrough.Breathable films that may be used include those made by 3M Company(SCOTCH®. microporous films), Exxon (Exxaire porous films) and AssiDomanBellcoat in Belgium. It is contemplated that other breathable films maybe used in the present invention.

The solid sheet portion 116 may be attached or bonded to the firstportion 112 and/or coating 114 by an adhesive or by heat bonding. Apreferred adhesive is a breathable-type adhesive. The solid sheetportion 116 is typically attached to the first portion 112 as shown, forexample, in FIGS. 12 and 14. Such an attachment or bond assists informing better defined channels for water drainage.

According to yet another embodiment of the present invention, aprotective drainage wrap 160 is shown in FIGS. 16 and 17. The protectivewrap 160 is adapted to be attached to sheathing or framing members. Theprotective wrap 160 includes a tape or strand portion 162, a yarnportion 164, a coating portion 166 and a solid sheet portion 168. Thetape portion 162 of FIGS. 16 and 17 includes a plurality of tapes in themachine direction, while the yarn portion 164 includes a plurality ofyarn strands in the transverse direction.

The tape portion 162 may be made of materials such as polyolefins,polyesters, nylons or combinations thereof. Examples of such materialsare described above with respect to the first portion 12, includingpolypropylenes or polyethylenes. The tape portion 162 may be made in asimilar manner as described above with respect to the machine directiontape 12 a.

The yarn portion 164 is capable of absorbing moisture such as water.Additionally, the yarn portion 164 may be capable of wicking themoisture which may provide further enhancement to the hydrationproperties. The yarn portion 164 may be made of the same materials andmay be installed in the same manner as described above with the yarnportion 64. It is contemplated that the strands of yarn portion 164 mayhave varying numbers of fibers or filaments twisted with each other suchthat the thicknesses of the strands differ. For example, the strands ofyarn portion 164 may alternate the number of fibers or filaments twistedwith each other to provide strands of varying thicknesses. The yarnportion 164 may be made of polymeric materials such as polyolefins(e.g., polypropylenes or polyethylenes), polyesters, nylons orcombinations thereof. Types of yarn that may be used include spun yarn,bulk continuous process (bcp) yarn and natural yarn (e.g., jute).

The yarn portion 164 and the tape portion 162 are preferably located indirections that are generally perpendicular to each other. This locationof the yarn portion 164 with respect to the tape portion 162 is depictedin FIG. 16. It is contemplated, however, that the yarn portion 164 maybe located generally diagonally from the tape portion 162 as long as theyarn portion 164 is in a generally downward position when installed.

As depicted in FIG. 16, each of the plurality of yarn strands of theyarn portion 164 is woven between the plurality of tapes/strands of thetape portion 162. When cross-woven, the combination of the yarn portion164 and the tape portion 162 may be referred to as a cross-woven scrim.The yarn portion 164 and the tape portion 162 may be woven by varioustechniques including with the use of a loom.

Alternatively, the tape portion 162 and the yarn portion 164 may becross-laminated (not shown) by adhering the plurality of tapes andplurality of yarn strands together via the use of a suitable adhesive.

The coating 166 may be made from polyolefins, polyesters, nylons andcombinations thereof as discussed above with respect to the coating 14.The solid sheet portion 168 may be made of polymeric materials such aspolyolefins, polyesters, nylons or combinations thereof. The solid sheetportion 168 may be a breathable film such as discussed above withrespect to the solid sheet portion 116.

The solid sheet portion 168 may be attached or bonded to the tapeportion 162, yarn portion 164 and/or coating 166. The solid sheetportion 168 is typically attached or bonded to the yarn portion 164 asshown, for example, in FIG. 17. The solid sheet portion 168 may be heatbonded to the yarn portion 164. The solid sheet portion 168 may also beattached to the yarn portion 164 by an adhesive (e.g., a breathable-typeadhesive).

Protective Wrap Additives

Additives to the protective wraps are contemplated in the presentinvention. For example, the protective wraps may include colorantadditives to resist the glare of the sun. The addition of colorantassists workers in installing the protective wrap. The protective wrapsmay also include chemical additives such as ultraviolet inhibitors andantioxidants to withstand deterioration from prolonged exposure tosunlight. In addition, the protective wraps of the present invention maybe translucent. Translucent protective wraps assist in locating studs,as well as window and door openings. The protective wraps of the presentinvention may also include printing thereon.

Properties of the Protective Wrap

The protective wraps of the present invention provide improved drainagecharacteristics. The protective wraps of the present invention alsoprovide for water vapor transmission rates (WVTR) as measured by ASTM E96, Procedure A. The woven portion of the protective wraps generallyhave water vapor transmission rates of from about 5 to about 15 perms.

The tensile strength of woven protective wraps as measured by ASTM D 882is generally greater than about 25 lbs/in. The tensile strength of wovenprotective wraps is preferably greater than about 30 lbs./in. and morepreferably greater than about 35 lbs/in. as measured by ASTM D 882. Itis beneficial that the protective wraps of the present invention arestrong so as to inhibit or prevent tearing and/or fraying during orafter installation. Tearing and/or fraying may, and typically will,result in unwanted air infiltration and/or moisture penetration.

The TD tear strength of woven protective wraps as measured by ASTM D1117 is generally greater than 25 lbs. The TD tear strength of wovenprotective wraps is preferably greater than about 30 lbs and morepreferably greater than about 35 lbs as measured by ASTM D 1117.

Non-woven protective wraps, such as breathable films, generally havewater vapor transmission rates of up to from about 30 or 60 perms asmeasured by ASTM E 96, Procedure A. The tensile strength of non-wovenprotective wraps as measured by ASTM D 882 is generally greater thanabout 15 lbs./in, and preferably greater than about 20 or 25 lbs./in.The TD tear strength of non-woven protective wraps as measured by ASTM D1117 is generally greater than 10 lbs, and preferably greater than about15 or 20 lbs.

The protective wraps of the present invention may be formed into anumber of shapes. The protective wraps, however, are generally stored ina roll on a circular cardboard core. The protective wraps of the presentinvention may be manufactured in a variety of sizes. Popular sizes usedin residential and commercial construction include, but are not limitedto, 3 foot by 100 foot (3′×100′), 4 5′×100′, 4.5′×150′, 4.5′×195′,9′×100′, 9′×150′, 9′×195′ and 10′×150′. For example, the 3′ lengthextends in the transverse direction, while the 100′ length extends inthe machine direction.

The thickness of the protective wraps may also vary, but is generallyfrom about 8 to about 12 mils as measured by ASTM D 751. The thicknessof the protective wraps is typically from about 9 to about 11 mils.Popular thickness of protective wraps includes about 10 mils.

Use of the Protective Wrap

The protective wraps of the present invention may be used as wraps inresidential and commercial buildings. The protective wrap is typicallycovered by an exterior covering like siding, brick, stone, masonry orconcrete veneer. Alternatively, the protective wraps of the presentinvention may be used as stucco drainage wraps in which the protectivewraps are covered by a cementitious exterior covering (stucco or EIFS).The protective wrap may also assist in controlling the drying/curingprocess of the cementitious exterior covering so that the hydration ofthe exterior covering will not occur too fast or too slow.

Methods of Applying the Protective Drainage Wrap

According to one process of the present invention, a protective drainagewrap is attached directly to sheathing which is attached to framingmembers. The sheathing may be made from various materials. Some examplesof materials used as sheathing include thin composite laminations,fiberboard, oriented-strand board (OSB), plywood, polyisocyanurate foam,extruded polystyrene (XPS) foam, and molded expanded polystyrene (EPS)foam. Some examples of framing members include plywood and OSB. Theprotective wraps may be attached mechanically to the sheathing by usingfasteners such as nails or staples.

One example of a protective wrap attached to a sheathing is shown inFIG. 15 where the protective wrap 110 (first portion 112, second portion114 and solid sheet portion 116) is installed over the sheathing 30. Thesheathing 30 is attached to a plurality of framing members 35. Types offraming members that may be used include southern yellow pine (SYP) andspruce pine fur (SPF). Some framing members, however, may be made ofmetal. The protective wrap 110 of FIG. 15 has been cut-away to depictthe first portion 112, the second portion 114 and the solid sheetportion 116. FIG. 15 also shows an exterior covering (siding 40) that islocated on an exterior surface of the protective wrap 110. The secondportion 114 is located adjacent to the siding 40 and assists in allowingwater to exit a wall system. The solid sheet portion 116 of FIG. 15 islocated adjacent to the sheathing 30

Another embodiment is shown in FIG. 5 with the protective wrap 10 thatincludes the first portion 12 and second portion 14. In FIG. 5, thesheathing 30 is attached to the plurality of framing member 35 and thefirst portion 12 is adjacent to the siding 40.

The protective drainage wrap 160 (tape portion 162, yarn portion 164,coating portion 166, and the solid sheet portion 168) is shown in FIG.18 over sheathing 70. The sheathing is attached to a plurality offraming members 75. The protective wrap 160 of FIG. 18 has been cut-awayto depict the tape portion 162, the yarn portion 164, coating portion166, and solid sheet portion 168. FIG. 18 also shows an exteriorcovering (siding 80) that is located on an exterior surface of theprotective wrap 160. The coating portion 166 is located adjacent to thesiding 80 and assists in allowing water to exit a wall system. The solidsheet portion 168 of FIG. 18 is located adjacent to the sheathing 70.

Another embodiment is shown in FIG. 8 with protective wrap 60 thatincludes tape portion 62, yarn portion 64 and coating 66. In FIG. 8, thesheathing 70 is attached to the plurality of framing members 75, and theyarn portion 64 is adjacent to the siding 80.

The sheathing 120 (FIGS. 13 and 14) may be attached in a similar fashionas described above with respect to protective drainage wraps 110 and160.

According to another process of the present invention (not shown), theprotective wrap is installed directly over a plurality of framingmembers. The protective wrap may be attached to the plurality of framingmembers in a similar manner as discussed above with respect to attachingthe protective wrap to the sheathing.

While the present invention has been described with reference to one ormore particular embodiments, those skilled in the art will recognizethat many changes may be made thereto without departing from the spiritand scope of the present invention. Each of these embodiments andobvious variations thereof is contemplated as falling within the spiritand scope of the claimed invention, which is set forth in the followingclaims.

1. A protective drainage wrap including: a mesh having materialextending in a first direction and in a second direction, the materialin the first direction including a polyolefin, polyester, nylon orcombinations thereof, the material in the second direction including apolyolefin, polyester, nylon or combinations thereof; and a coatingapplied to the mesh to form a plurality of interstices, the intersticesbeing configured to facilitate transfer of water vapor therethrough. 2.The protective drainage wrap of claim 1, wherein the coating includes apolyolefin, polyester, nylon or combinations thereof.
 3. The protectivedrainage wrap of claim 1, wherein the wrap includes a plurality ofperforations formed therethrough.
 4. The protective drainage wrap ofclaim 3, wherein the perforations are between about 3 mils to 15 mils.5. The protective drainage wrap of claim 1, wherein the coating has athickness between about 0.5 mil and 2.0 mils.
 6. The protective drainagewrap of claim 1, wherein the first direction material and coating have acombined thickness between about 8 mils and 10 mils.
 7. The protectivewrap of claim 1, wherein the mesh is cross-woven.
 8. The protective wrapof claim 1, wherein the mesh is cross-laminated.
 9. The protective wrapof claim 1, wherein the first direction material and the seconddirection material include a plurality of tapes.
 10. The protective wrapof claim 1, wherein the first direction material has a first thickness,the second direction material has a second thickness, and the secondthickness is at least about twice the first thickness.
 11. Theprotective wrap of claim 1, wherein the permeability of the protectivedrainage wrap is controlled by applying the coating with a predeterminedthickness to the mesh to form a plurality of interstices ofpredetermined size.
 12. The protective wrap of claim 1, wherein thefirst direction material and the second direction material are the same.13. The protective wrap of claim 1, wherein the first direction materialand the second direction material are different.
 14. The protective wrapof claim 1, wherein the second direction material is yarn.
 15. A methodfor forming a protective drainage wrap including: providing a meshhaving material extending in a first direction and in a seconddirection, the material in the first direction including a polyolefin,polyester, nylon or combinations thereof, the material in the seconddirection including a polyolefin, polyester, nylon or combinationsthereof; and applying a coating to the mesh to form a plurality ofinterstices configured to facilitate transfer of water vaportherethrough.
 16. The method of claim 15, further including the step ofcontrolling the permeability of the protective drainage wrap by applyingthe coating with a predetermined thickness to the mesh to form aplurality of interstices of predetermined size.
 17. The method of claim15, wherein the coating includes a polyolefin, polyester, nylon orcombinations thereof.
 18. The method of claim 15, further includingmaking a plurality of perforations through the protective drainage wrap.19. The method of claim 18, wherein the perforations are between about 3mils to 15 mils.
 20. The method of claim 15, wherein the applied coatinghas a thickness between about 0.5 mil and 2.0 mils.
 21. The method ofclaim 15, wherein the first direction material and coating have acombined thickness between about 8 mils and 10 mils.
 22. The method ofclaim 15, wherein the mesh is cross-woven.
 23. The method of claim 15,wherein the mesh is cross-laminated.
 24. The method of claim 15, whereinthe first direction material and the second direction material are madefrom a plurality of tapes.
 25. The method of claim 15, wherein the firstdirection material has a first thickness, the second direction materialhas a second thickness, and the second thickness is at least about twicethe first thickness.
 26. The method of claim 15, wherein the firstdirection material and the second direction material are the same. 27.The method of claim 15, wherein the first direction material and thesecond direction material are different.
 28. The method of claim 15,wherein the second direction material is yarn.